Crystalline PLA Filaments to Prevent 3D Printer Jamming
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Solution Overview
Problem
Conventional PLA filaments used in additive manufacturing (FDM/FFF) suffer from premature softening due to low glass transition temperatures, leading to printer jams and inconsistent feeding, especially in large prints and dual-extrusion applications, without effective solutions that maintain printing quality, speed, or reduce complexity.
Innovation Solution
Manufacture PLA filaments with high crystallinity by heat-treating spooled amorphous filaments above the glass transition temperature to induce crystallization, maintaining filament dimensions and reducing heat-induced softening, using nucleating agents if needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional amorphous PLA filaments are used in additive manufacturing, then the printing process is simple and equipment requirements are low, but the filaments suffer from premature softening due to low glass transition temperature, causing printer jams and inconsistent feeding
Solution Approach 1:
The patent changes the physical-chemical parameter of the PLA filament by inducing crystallization through heat treatment above the glass transition temperature. This transforms the amorphous PLA into semi-crystalline PLA, fundamentally changing its thermal properties and raising the softening temperature, thereby improving feeding consistency without requiring printer modifications
Solution Approach 2:
The patent applies preliminary heat treatment to the PLA filaments before they are used in printing. By pre-crystallizing the filaments through controlled heating above Tg and subsequent cooling, the filaments gain improved thermal stability and dimensional consistency before being loaded into the printer, preventing premature softening during the printing process
2Temperature
If the glass transition temperature of PLA is increased through crystallization, then heat-induced softening is reduced and feeding consistency is improved, but additional heat treatment equipment and process complexity are required
Solution Approach 1:
The patent utilizes the inherent thermal properties of PLA to achieve crystallization. By heating the amorphous PLA above its glass transition temperature and allowing it to cool, the material self-organizes into a semi-crystalline structure without requiring external catalysts or complex chemical treatments, simplifying the manufacturing process
Solution Approach 2:
The patent exploits the phase transition of PLA from amorphous to semi-crystalline state through controlled heating and cooling cycles. This phase transition naturally increases the glass transition temperature and improves thermal stability, providing a straightforward manufacturing approach that leverages the material's inherent phase change behavior
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The crystalline PLA filaments exhibit improved resistance to heat-induced softening, reducing printer jams and ensuring consistent feeding, while maintaining printing quality and avoiding the need for additional cooling or complex printer modifications.
Implementation Method 1
heat-treating spooled amorphous filaments above the glass transition temperature to induce crystallization
Implementation Method 2
low glass transition temperatures, leading to printer jams
Data Source
AI summary
Provided is a new and better solution to the problems associated with the premature softening of PLA filaments in the additive manufacturing of three dimensional articles. It is based upon the finding that poly (lactic acid) filaments with high crystallinity offer much better resistance to heat-induced softening. The crystalline poly (lactic acid) filament can accordingly be used in the additive manufacturing of three dimensional articles without encountering the problems associated with premature softening, such as poor quality and printer jamming. The crystalline poly (lactic acid) filaments can also be used in additive manufacturing of three dimensional articles without compromising the quality of the ultimate product, reducing printing speed, increasing cost, or leading to increased printer complexity. It more specifically discloses a filament for use in three-dimensional printing which is comprised of crystalized poly (lactic acid), wherein said filament has a diameter which is within the range of 1.65 mm to 1.85 mm.